锌电解槽内电解液的水力学及数值模拟研究
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摘要
在锌的生产工序中,电解沉积是能耗最高的工序,因此,降低电积的能耗对提高企业效益,使企业在竞争中占有一席之地意义重大。
本课题主要研究的是电解槽内的流体流场,及改善流场的措施。依据某公司的锌电解槽,分别进行了水力学试验和数值模拟研究,以进一步观察其内部规律。水力学试验方面,依据相似原理,按照1：5的相似比采用有机玻璃制作电解槽水模型试验装置,采用水模拟电解液。利用测电导率法来获得平均停留时间(RTD),利用观察法和照相法来获取电解槽内部的流场信息。数值模拟方面,采用专业CFD商业软件Fluent对所建立的水模型进行数值模拟。并将模拟结果与水模型试验结果进行对比,来证明模拟方法的准确性和可靠性。并在该数值模型的基础上对实际工业生产上电解槽内部的电解液流场和温度场信息进行模拟预测。
研究结果表明：现行生产条件下的最佳流量为2.33L/min。原水口管型在不同浸入深度和不同流量下的最佳条件是：2.33L/min,7cm。当分别使用设计制作的另外6种进液管水口管型时,从1#至6#管型,不同流量和不同深度的最佳条件分别为：2.33L/min,7cm;2.98L/min,7cm;3.58L/min,9cm;2.98L/min, 7cm;2.33L/min,9cm;2.33L/min,3cm。经综合比较后认为采用4#水口管型,控制流量为2.98L/min,浸入深度为7cm,溶液在该最佳条件下要比现行生产条件下的平均停留时间多273s。
采用Fluent软件对锌电解槽的流场和温度场进行了数值模拟初步研究,结果显示：电解槽中的流体运动规律与水力学实验结果基本一直。同时预测了工业电解槽中流场和温度场,为进一步改善和优化电解槽结构、增大电解槽容量提供了合理的理论依据。
The electrolytic deposition process is the highest energy consumption step in the zinc production process. Therefore, reducing the energy consumption of it to improve enterprise efficiency places an important significance in the competitive supermarket.
This paper mainly focused on the flow and the flow field in electrolytic cell and measures of improving the flow field. Mechanics experiments and numerical simulation were carried out according to electrolytic tank in a company to further study their internal rules. In terms of mechanics experiment, electrolytic cell water model tester was used with PMMA of similar ratio of 1:5 and water modeling electrolyte based on similarity principles. Conductivity measurements were used to RTD, observation and photography were taken to obtain the flow field information within the cell. In aspect of numerical simulation, a professional commercial software CFD Fluent was used for numerical simulation to the built water model and experimental results were compared to ones of water model so as to prove the accuracy and reliability of simulation. Based on the numerical model, the author also made prediction about electrolyte flow field and temperature field within the cell in the actual industrial production.
The results showed that the best flow under the existing conditions of production was 2.33L/min. The best conditions for the original outlet tube were immersion depth 7cm and flow 2.33L/min. There were 6 different kinds of designed outlet tubular from 1 # to 6 # tube, the optimal conditions of different flow and different depth separately were:2.33L/min,7cm; 2.98L/min,7cm; 3.58L/min,9cm; 2.98L/min,7cm; 2.33L/min,9cm; 2.33L/min,3cm. After comprehensive,4 # was proved to be the proper one which could stay 273s longer than the average length in the current production condition.
Fluent software was used preliminarily to simulate the flow field and temperature field of zinc electrolytic cell in the study, the results showed that the fluid movement in the cell was consistent with the mechanics experiment and also forecast the flow field and temperature field in industrial electrolytic cell which provided a reasonable theoretical basis for further improving and optimizing the cell structure and increasing the cell capacity.
本课题主要研究的是电解槽内的流体流场,及改善流场的措施。依据某公司的锌电解槽,分别进行了水力学试验和数值模拟研究,以进一步观察其内部规律。水力学试验方面,依据相似原理,按照1：5的相似比采用有机玻璃制作电解槽水模型试验装置,采用水模拟电解液。利用测电导率法来获得平均停留时间(RTD),利用观察法和照相法来获取电解槽内部的流场信息。数值模拟方面,采用专业CFD商业软件Fluent对所建立的水模型进行数值模拟。并将模拟结果与水模型试验结果进行对比,来证明模拟方法的准确性和可靠性。并在该数值模型的基础上对实际工业生产上电解槽内部的电解液流场和温度场信息进行模拟预测。
研究结果表明：现行生产条件下的最佳流量为2.33L/min。原水口管型在不同浸入深度和不同流量下的最佳条件是：2.33L/min,7cm。当分别使用设计制作的另外6种进液管水口管型时,从1#至6#管型,不同流量和不同深度的最佳条件分别为：2.33L/min,7cm;2.98L/min,7cm;3.58L/min,9cm;2.98L/min, 7cm;2.33L/min,9cm;2.33L/min,3cm。经综合比较后认为采用4#水口管型,控制流量为2.98L/min,浸入深度为7cm,溶液在该最佳条件下要比现行生产条件下的平均停留时间多273s。
采用Fluent软件对锌电解槽的流场和温度场进行了数值模拟初步研究,结果显示：电解槽中的流体运动规律与水力学实验结果基本一直。同时预测了工业电解槽中流场和温度场,为进一步改善和优化电解槽结构、增大电解槽容量提供了合理的理论依据。
The electrolytic deposition process is the highest energy consumption step in the zinc production process. Therefore, reducing the energy consumption of it to improve enterprise efficiency places an important significance in the competitive supermarket.
This paper mainly focused on the flow and the flow field in electrolytic cell and measures of improving the flow field. Mechanics experiments and numerical simulation were carried out according to electrolytic tank in a company to further study their internal rules. In terms of mechanics experiment, electrolytic cell water model tester was used with PMMA of similar ratio of 1:5 and water modeling electrolyte based on similarity principles. Conductivity measurements were used to RTD, observation and photography were taken to obtain the flow field information within the cell. In aspect of numerical simulation, a professional commercial software CFD Fluent was used for numerical simulation to the built water model and experimental results were compared to ones of water model so as to prove the accuracy and reliability of simulation. Based on the numerical model, the author also made prediction about electrolyte flow field and temperature field within the cell in the actual industrial production.
The results showed that the best flow under the existing conditions of production was 2.33L/min. The best conditions for the original outlet tube were immersion depth 7cm and flow 2.33L/min. There were 6 different kinds of designed outlet tubular from 1 # to 6 # tube, the optimal conditions of different flow and different depth separately were:2.33L/min,7cm; 2.98L/min,7cm; 3.58L/min,9cm; 2.98L/min,7cm; 2.33L/min,9cm; 2.33L/min,3cm. After comprehensive,4 # was proved to be the proper one which could stay 273s longer than the average length in the current production condition.
Fluent software was used preliminarily to simulate the flow field and temperature field of zinc electrolytic cell in the study, the results showed that the fluid movement in the cell was consistent with the mechanics experiment and also forecast the flow field and temperature field in industrial electrolytic cell which provided a reasonable theoretical basis for further improving and optimizing the cell structure and increasing the cell capacity.
引文
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